400awhp plan let me know what you think!

[DSM_Newblet]

Hey! Just picked up a 91 Vr4 about a month ago with 93k original for a steal so decided I would build it, go figure. The plan is 400awhp streetable and even, fingers crossed, daily driveable. Well here is a list of the mods, after much research, I was thinking to reach my goal. (excluding maintenance, tranny, tcase, etc. because I have already got those taken care of.) All input, advice, other options, experiences and all around comments are appriciated.

Also keep in mind I will be running e85 as I live right down the street from the pump and love the stuff!
List may be a little out of order, have spelling errors and maybeeven missing some stuff so I appologize in advance, again feel free to comment on anything.

Cams - Crower 272/272
Springs/retainers - Manley single spring and titanium retainers
Fuel pump - rewired walbro 255
AFPR - already have an aftermarket afpr on there not sure what brand, came with the car, but might keep it as it looks to be working properly)
Injectors - FIC blue max low z 1350cc (what do you guys think for e85 on the hx35?)
Ecu management - ECULink v3 full or lite(not sure if running SD or not, suggestions?) with the EPROM
Turbo - Hx35 8 blade with BEP housing (not sure how many psi I will run just yet for my goal, maybe 23-26?)
Exhaust mani - 2g ported
02 housing - MAP 38mm external wastegate recirc to exhaust ( Is this a good size or bigger?)
FMIC - ETS 10inch FMIC kit
BOV - TiAL 50mm Q recirc BOV
MBC - Voodoo MBC
Gauges - Not sure on brand yet, but wideband a/f and boost
Exhaust - No idea need to do more research of what will fit but definately 3inch no CAT

So that's about it for now, somethings may be too much for the goal or not enough so just let me know. I will continue to do more research and add to the list while also considering all input.

THANKS GUYS!

 

[901gtsi]

WOW! Thank you guys so much for all of the advice, did not expect this many posts. Much love! I will
definately be looking into a walbro 450, as for the FMIC I was just going the ETS route because it is the only kit I know made for a Gvr4. But I guess I could always just take the dimesions of that intercooler and find one the same size and make/look for piping matching the ETS kit that also fits. Also going to look into the punishment housing and TiAL set up, and more of your guys suggestions. And I forgot the dudes name but it is a white 91 890/2000 from Tuscon.

I saw this car on craigslist a while back and wanted to pick it up but didn't have the money. I think it had a little front end damage so the guy was selling it for a really good price. Good luck on your build man.

 

[Greedy Pimp]

Well I had an evo 3 16g with a 255 rewired fp, fic 1150 injectors at about 83 idc. Boost was at 27 dropping to 24 on e85. You really don't want to go above 90% idc so I would go as big injectors as u can buy. 1000 cc injectors on e85 made 400whp. That's close to 500 crank hp with 1000cc injectors, what was your idc? What air fuel ratio do u shoot for wot? Crash89.

Right now with my fp bb black on fic 2150cc injectors, with rewired 450 fuel pump and boost at 32psi, I see about 72% Idc.

 

[combs-dsm]

Oh yeah! Would you guys recommend a balance shaft delete for this set up? I won't be going over a 8k rev liimit. Not sure if it will be necessary or not.

Always remove the balance shafts like said before. To much to wprry about as it is. But if you remove them. Make sure to port your OFH as well. Theres awesome write ups on here about how to do both.

You can get all your stuff for the BSE thru the dealer and it doesnt cost much at all.

 

[crash89]

Well I had an evo 3 16g with a 255 rewired fp, fic 1150 injectors at about 83 idc. Boost was at 27 dropping to 24 on e85. You really don't want to go above 90% idc so I would go as big injectors as u can buy. 1000 cc injectors on e85 made 400whp. That's close to 500 crank hp with 1000cc injectors, what was your idc? What air fuel ratio do u shoot for wot? Crash89.

Right now with my fp bb black on fic 2150cc injectors, with rewired 450 fuel pump and boost at 32psi, I see about 72% Idc.

As of now, I see about 89-91% IDCs on my 1000s @ 26 peak boost falling to 24 by redline. AFRs are 12.1-12.3 throughout, 15* peak timing. Still pretty conservative.

Oh yeah! Would you guys recommend a balance shaft delete for this set up? I won't be going over a 8k rev liimit. Not sure if it will be necessary or not.

As said numerous times, sure its in your best interest to do so. However, I run my stock 7 bolt to 8k with balance shafts and I dont even worry. With a properly maintained/timed engine you shouldnt really have any worries to run with balance shafts at that power level. Now, over 8k would probably be pushing it and you'd want to remove them. They do turn what, 4 to 6 times the crankshafts rotations? Thats a shit ton of R's..

 

[iBoostDSM]

Check out my mods list! I have an almost identical setup to what you want to do.

 

[Vdubzr32]

Nice first starters set up

 

[lars y]

About the FIC 2150s on extremepsi:

The internal construction of this 2150cc/min injector includes a seal that has been found to swell when in contact with MTBE from oxygenated fuels like Q16 or VP Import. This swelling causes a significant reduction in flow through the injector and therefore renders it unsuitable for use with MTBE oxygenated fuels. Please strictly follow the care instructions for these injectors since there are potential corrosion issues that may arise from prolonged disuse while exposed to alcohol based fuels (E85, etc.)

Am i misunderstanding, or are they saying the seals will swell when using E-85?

 

[Archer Fabrications]

No it says when exposed to mis use. That site was already quoted. These injectors are made for e85

 

[fran_drivertsi]

Oh yeah! Would you guys recommend a balance shaft delete for this set up? I won't be going over a 8k rev liimit. Not sure if it will be necessary or not.

Keep your balance shafts, son. You'll thank me later.

 

[renovatdkitchen]

Keep your balance shafts, son. You'll thank me later.

Depends on the person. I have 90A engine mounts, no balance shafts, a 6 puck unsprung clutch, daily drive my car and dont mind it at all.

 

[BogusSVO]

I vote for the BSE, just one less thing to fail.

 

[Archer Fabrications]

I vote for the BSE, just one less thing to fail.

yep, you'll thank us later. probably more than you'll thank the other guy when the bearing spins some day.

 

[boost97gst]

Keep the front jsut cut the belt. Rear: take it out replace with oem stubby.

 

[DSM_Newblet]

I saw this car on craigslist a while back and wanted to pick it up but didn't have the money. I think it had a little front end damage so the guy was selling it for a really good price. Good luck on your build man.

Yeah the core support is bent in a tiny bit but no frame damage, it was also missing alot of interior plastics but one trip to the salvage yard took care of that. No rust which is great for it being from Massachusetts. The car is daily driveable right now but does need a little work, mainly cosmetic.

Check out my mods list! I have an almost identical setup to what you want to do.

Very nice dude! Do you daily it?

 

[iBoostDSM]

It's driven pretty much everyday! A little less often while I'm at school though because everything's in walking distance.

It's a very fun street car, and as long as maintanence is all done it should give you no problems!

 

[DSM_Newblet]

It's driven pretty much everyday! A little less often while I'm at school though because everything's in walking distance.

It's a very fun street car, and as long as maintanence is all done it should give you no problems!

Yeah mine will mainly just see about 40miles of highway a day, too and from work and the occasional joy ride.
It's out getting the tranny street built/rebuild and all maintenance done as we speak.
Got a great deal on the tranny build and all the belts changed, pulleys, water pump, MLS head gasket, arp head studs, valve seals, clutch and pressure plate, and resurfaced head and all of the fluid changed of course. Should get it back later this week, then it is time to buildsome power!

 

[BogusSVO]

You said a key word for me!

Post up a pic of the surface on the head you had done.

 

[DSM_Newblet]

You said a key word for me!

Post up a pic of the surface on the head you had done.

Like I said I have a dude that hooked me up with all of this work being done so I will see if he can send me a pic of the head when it is done. What was the keyword?

 

[BogusSVO]

With a MLS HG surface finish has to be perfect. Glass smooth, if it is not chances are not good for the HG to seal.

http://www.dsmtuners.com/forums/new...face-4g63t-cylinder-head-mls-head-gasket.html

If the HG surface looks like this...
http://www.dsmtuners.com/forums/cyl...0613-why-not-let-your-head-belt-surfaced.html

I wish you the best of luck with the MLS.

By rights for a MLS the block should be decked too.
http://www.dsmtuners.com/forums/cyl...-deck-4g63-cast-iron-block.html#post152790451


By this time in the life of a turbo 4G63 engine, chances are it has had a few HG jobs done, so the over heating, and quick cleaning methods have taken a toll on the block's HG surface.

The keyword? Simple, You said you had a head surfaced. I always like to see that.

I am a bit of a stickler for surface finishes.

 

[BogusSVO]

With a MLS HG surface finish has to be perfect. Glass smooth, if it is not chances are not good for the HG to seal.

http://www.dsmtuners.com/forums/new...face-4g63t-cylinder-head-mls-head-gasket.html

If the HG surface looks like this...
http://www.dsmtuners.com/forums/cyl...0613-why-not-let-your-head-belt-surfaced.html

I wish you the best of luck with the MLS.

By rights for a MLS the block should be decked too.
http://www.dsmtuners.com/forums/cyl...-deck-4g63-cast-iron-block.html#post152790451


By this time in the life of a turbo 4G63 engine, chances are it has had a few HG jobs done, so the over heating, and quick cleaning methods have taken a toll on the block's HG surface.

The keyword? Simple, You said you had a head surfaced. I always like to see that.

I am a bit of a stickler for surface finishes.

 

[Archer Fabrications]

Ha like that belt sanded job you had come in? WOW...... people these days...

Has to be done right, has to be milled. I run a felpro permatorque.

 

[KiNg MaRtY]

Also being a GVR-4 guy, go with the ETS unit. Direct bolt on an it will be hassle free compared to piecing up a unit.
Also, compared to the 1g and 2g, we have much less room making it more difficult to install bigger turbos. The lower tranny mount will also be an obstacle. You will have to clock the HX turbo and get either a smaller radiator or one that will fit in place of the condenser.

 

[BogusSVO]

Urbansmoker, If you think the belt surfacer is bad, check out what a table stone surfacer will do.

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I doubt 2 cans of copper coat and a double staked composite gasket would have sealed that head.

It was all sorts of mangled.

 

[Archer Fabrications]

Wow... Not even worth trying any other method than a mill.

 

[92AWDHX40]

Im shooting for the same hp levels similar to johns 92 tsi he has fairly simple set up and made around 380 hp on the 2g maf and stock internals. Im going sd, possible hx 35 and bigger injectors. I have a fresh build with the head decked and block. any imperfection can cause a problem im glad I kept my felpro gasket, fills in imperfections with even my block being smooth.